Electrically insulating thermal connector having a low thermal resistivity

Abstract

A thermal connector comprising an electrically insulating beam having a first end face at a first end and a second end face at a second end is provided. The second end face may be opposite the first end face in an X direction. The beam may have a width in a Y direction perpendicular to the X direction. The beam may also have a top face and a bottom face offset from the top face in a Z direction. The thermal connector may include a first terminal attached to the bottom face and adjacent the first end and a second terminal attached to the top face and adjacent the first end. The connector may have an overall thickness in the Z direction, which includes the first and second terminals and is greater than 1.27 mm and less than 3.81 mm.

What is claimed is: 
     
       1. A thermal connector comprising:
 an electrically insulating beam having a first end face at a first end and a second end face at a second end, the second end face opposite the first end face in an X direction, the beam having a width in a Y direction perpendicular to the X direction, the beam having a top face and a bottom face which is offset from the top face in a Z direction, the Z direction being perpendicular to each of the X and Y directions; 
 a first terminal attached to the bottom face and adjacent the first end; and 
 a second terminal attached to the top face and adjacent the first end; 
 a conductive trace formed on the electrically insulating beam and configured to provide electrical tuning. 
 
     
     
       2. The thermal connector of  claim 1 , wherein the electrically insulating beam comprises a material having a thermal conductivity from about 150 W/m° C. to about 300 W/m° C. at about 22° C. 
     
     
       3. The thermal connector of  claim 1 , wherein the electrically insulating beam comprises aluminum nitride. 
     
     
       4. The thermal connector of  claim 1 , wherein the electrically insulating beam comprises beryllium oxide. 
     
     
       5. The thermal connector of  claim 1 , further comprising:
 a third terminal attached to the bottom face and adjacent the second end; and 
 a fourth terminal attached to the top face and adjacent the second end. 
 
     
     
       6. The thermal connector of  claim 1 , further including a first end face terminal attached to the first end face of the beam and connecting the first terminal with the second terminal. 
     
     
       7. The thermal connector of  claim 1 , further including a second end face terminal attached to the second end face of the beam and connecting the third terminal with the fourth terminal. 
     
     
       8. The thermal connector of  claim 1 , wherein the first terminal spans the width of the beam across the first end face of the beam. 
     
     
       9. The thermal connector of  claim 1 , wherein an overall length of the thermal connector is between about 2.5 mm and about 12.7 mm. 
     
     
       10. The thermal connector of  claim 1 , wherein an overall width of the thermal connector is between about 5.1 mm and about 10.2 mm. 
     
     
       11. The thermal connector of  claim 1 , wherein the thermal resistance of the thermal connector is between about 2° C./W and about 10° C./W at about 22° C. 
     
     
       12. The thermal connector of  claim 1 , wherein the overall thickness is between about 1.4 mm and about 2.16 mm. 
     
     
       13. The thermal connector of  claim 1 , wherein the thermal connector has an overall length between 3.2 and 4.9 times the overall thickness of the thermal connector. 
     
     
       14. The thermal connector of  claim 1 , wherein the thermal connector has an overall length between 5 and 6.2 times the overall thickness of the thermal connector. 
     
     
       15. The thermal connector of  claim 1 , wherein the thermal connector has an overall length in the X direction, and each of the overall length and the overall width of the thermal connector is between about 8.9 mm and about 10.2 mm. 
     
     
       16. The thermal connector of  claim 1 , wherein at least one of the first terminal or the second terminal comprises gold. 
     
     
       17. The thermal connector of  claim 1 , wherein at least one of the first terminal or the second terminal comprises a magnetized material. 
     
     
       18. The thermal connector of  claim 1 , wherein at least one hole is formed in the beam to provide electrical tuning. 
     
     
       19. A thermal connector comprising:
 an electrically insulating beam having a first end face at a first end and a second end face at a second end, the second end face opposite the first end face in an X direction, the beam having a width in a Y direction perpendicular to the X direction, the beam having a top face and a bottom face which is offset from the top face in a Z direction, the Z direction being perpendicular to each of the X and Y directions; 
 a first terminal attached to the bottom face and adjacent the first end; and 
 a second terminal attached to the top face and adjacent the first end; 
 wherein at least one hole is formed in the electrically insulating beam to provide electrical tuning. 
 
     
     
       20. The thermal connector of  claim 19 , wherein the electrically insulating beam comprises a material having a thermal conductivity from about 150 W/m·° C. to about 300 W/m·° C. at about 22° C. 
     
     
       21. The thermal connector of  claim 19 , wherein the electrically insulating beam comprises at least one of aluminum nitride or beryllium oxide. 
     
     
       22. The thermal connector of  claim 19 , further comprising:
 a third terminal attached to the bottom face and adjacent the second end; and 
 a fourth terminal attached to the top face and adjacent the second end.